Development of a Distributed Control System Using PLC: Report

This report details the development of a Distributed Control System (DCS) using Programmable Logic Controllers (PLCs). The project aimed to create an economical DCS for industrial use, develop ladder logic for PLC programming, implement sensors, control motor speed, and thoroughly test the system. The author, acting as team leader, focused on team motivation, project model development, and electrical circuit connections. Key aspects included MODBUS communication for linking multiple PLCs and addressing challenges in integrating PLCs and sensors using a centralized control system. The project emphasized cost-effectiveness through strategic hardware selection without compromising quality. The report also highlights the collaborative effort required for successful project delivery, covering both hardware and software configurations and leading to the successful deployment of an automated system capable of running during maintenance and upgrades.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 2

CE 2.1 Project Information
Name of the project: Development of a distributed control system using PLC
Location of the project: [PLEASE FILL]
Project Duration: [PLEASE FILL]
Organization: [PLEASE FILL]
Role and Designation during the time: Team Leader
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
Automation has become one of the major application in which every sector of the world
is trying to explore something new and enhance the existing system. I was appointed as the team
leader in this project in which I had to develop a DCS (Distributed Control System) that can
allow automated delivery of the operational activities in a manner to accomplish the necessary
objectives and provide necessary output for the organization. I embedded PLC that allows the
development of the computer-based control system that can be helpful in monitoring, controlling,
and simulating the industrial automation processes. I kept the project efficient enough to be
capable of dealing with the decentralization, concurrency, and time. I implemented one PLC as
the master of the entire system and other decentralized systems would be managed through the
PLC itself. I used MODBUS protocol in a manner to allow communication between the two
PLCs and a single LCD has been used for monitoring the data.

CE 2.2.2 Objectives developed for the project
The completion of the project within the estimated deadline was the most prior objective
for me and so I developed the following set of the objectives in a manner to accomplish the
project constraints successfully:
 To develop a DCS system using a network of PLC's that would be economical for
industry
 To develop Ladder Logic for PLC
 To implement sensors within the entire developed automated system
 To control the speed control of the motor
 To test the developed system
CE 2.2.3 My area of work
I had to motivate and manipulate the team members toward accomplishing the objectives
mentioned above and make sure that the project being delivered is on the track. I managed a
different relationship among different team members and I made sure that the every team
member better understand their roles and responsibilities for accomplishing the project
constraints without altering the standard and quality of the project. I assigned myself with the
development of the model of the entire project in addition to the electronic and electrical circuit
connections. I had to embed the Control Circuit terminal’s function as described below:
Symbol Factory Setting Function
REV Reverse Run Multi-Function input2

For Forward Run Multi-Function input
SPH High speed Multi-Function input4
RST Reset Multi-Function input3
SPL Low speed Multi-Function input6
SPM Medium speed Multi-Function input5
+ 10 + 10 Power supply for analog
freq.
GND Ground common for input
terminals
AI 4 - 20mA corresponding to
the high operating frequency
Analog frequency reference
input(current)
VI 0 - +10V corresponding to
the high operating frequency
Analog frequency reference
input(voltage)
AM 0 -10V Digital frequency output
Terminal
FA
FB
FC
Fault relay output
3A/250VAC, 3A/30VDC
Multifunction output terminal 3
DRV Optical couple output DC
24V/100mA
Multi-function output
terminal 1

I installed LCD display, connected I/O port of the trainer board, and RS-232 port
through which I connected the PC through the PLC and proposed the design of the trainer board
for the PLC that was available within the electric machine.
Figure 1: Trainer board for PLC
MODBUS communication was another concerning sector for my project where I
hosted the computer or the controller by connecting the 32 controllers within the utilized RS-485

port of PLC. I used the daisy chain fashioned twisted pair cable that was connected to the 120-
ohm pull resistor. Since, both the wires were not interchangeable and so, I wired both of the
wires, in the same way, considering that the wire length should not be exceeding 4000 feet (1200
meters).
CE 2.2.4 Project Group
CE 2.2.5 My responsibilities throughout the project
I was responsible for the management of the team and assuring that the developed project
will be efficient and cost-effective in a manner to be utilized within the industries. I kept the
project cost-effective through buying and implementing hardware those were capable of
delivering the same output at low cost without altering the standard and quality. I was

responsible for establishing the components as those were estimated while designing the entire
system.
CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
The present scenario in the industries, deliver automated services, however, the efficiency
and effectiveness can be enhanced through installing the PLC within the existing environment
and allowing the machines to deliver the real-time deliverables. The project needed the hardware
and software skills in a manner to manage the efficiency and effectiveness of the proposed
system. The DCS system was developed using the PLC that would be dominating over other
PLCs in a manner to accomplish the entire operational activities in an automated manner. The
dominating PLC will be monitoring the entire process being accomplished by other sensors and
the PLCs in a manner to track the ongoing process and activities of the PLCs. The MODBUS
protocol has been utilized for the implementation of the communication between the
implemented PLCs in addition to the installed LCD that will be displaying the output and
executing data.
CE 2.3.2 Engineering knowledge and skills applied in the project
Hardware description can be provided as:
 Power supplies
 PLC
 C LCD display
 Connection cables

 Motor
 PUMA mini-series AC drive
 Sensors
I set the hardware implementation based on the following diagram:
Figure 2: Diagram of PLC
I had to assure that the input and output power is enough to operate the PLC and so I
implemented a power supply module that will be helpful in converting the 24 V DC supply to the
necessarily required voltage and for the voltages of the sensors and the actuators, the user will
have to provide additional power supplies. I managed the components those are compatible with
the input/output module of the power supply. I used AC drives for the accomplishment of the
following operations:
 Smoother operation
 Controls the speed of the motor
 Adjust the rate of production
 To restrict the energy consumption

 Controls torque
 The mechanical shock in stop and start situations will be limited
I used Reed Switch and PT100 sensors for allowing the connections between the
components through using the magnetic field leading towards the close or open circuit.
PT100 is a temperature sensor that will allow manipulation in the resistance with the
varying temperature.
CE 2.3.3 Identified issues and their solutions
2.3.3.1 Issues
The incorporation of the various PLCs and sensors within every sector of the industries
was one of the major obstacles in delivering the project that is decentralized and needs to be
managed at a single platform. I identified that there should be a centralized computer or system
that will be capable of monitoring and controlling every other aspect of the project.
2.3.3.2 Solutions
I suggested incorporating the MODBUS protocol that will allow the entire system to be
controlled by a single computer and accomplish the necessary deliverables and outputs without
altering the standard and quality. This allowed the existence of a centralized system that can
overwrite and control the rest of the systems of the industry.
CE 2.3.4 Plan to produce creative and innovative work
Previous attempts were driven to enhance the quality of the single voice calls however, I
drive an attempt that can be implemented within the entire configuration of the automated
network and managed to propose a solution that can be helpful in enhancing the entire

operational activities of an industry. I used a dominant PLC that will be helpful in controlling the
other PLCs and sensors embedded throughout the industry and thus, will allow the administrator
to overwrite for the instances where additional assistance is required. I kept the project to be
applicable even if the project is under maintenance or upgrade.
CE 2.3.5 Collaborative work
The project would not be completed without the effort of the every team members
involved in the project as deep knowledge from different backgrounds and practices were
necessary to deliver the project successfully. I assigned different jobs to the team members and
asked them to complete within the expected time. I was leading the team and managed an
effective communication between the team members and keep the conflicts far away from the
project and deliver the necessary output. The collaborative work led to the establishment of the
hardware including sensors, automatic arms, conveyor belts and others, and software
configuration.
CE 2.4 Project Review
CE 2.4.1 Project Overview
I developed an automated system that will be efficient and effective enough to be
operated for the automatic functioning of the operational activities within the industry through
PLC. A centralized system was introduced efficient enough to be operated by an automated
system under the control of an administrator. It is an obvious factor that the project should be
capable of running even during the instance of the maintenance and upgrade. Thus, I developed
the system that will be working eve of the entire system is under upgrade or maintenance.

CE 2.4.2. My contribution to the Work
I contribute in the smooth management of the team and establishing a bond that was
helpful in leading better communication between the team members assuring successful delivery
of the project. I managed to integrate the PLC throughout the existing systems and thus, allowing
automation within the industries for the delivery of operational activities. I developed framework
and model of the entire system that allowed rest of the team members to proceed with the project
accordingly. I contributed in the successful evaluation and delivery of the project that landed in
positive manner and the project was successfully deployed.